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"#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ___PPT9345679:;<=>?@AI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4}  ` fffff` ?̙ffE` ff333` C3ff3` &u3` ffff` **@fff̙fl` +3[Xd` 333f` 5D`|f>?" dd@*?lPd@ `F `A@`<``( n?" dd@   @@``PP   @ ` `.p>> P 6(  6T ```  "```"  BPG p"P`` F 0C B  C BCE6FGIQSTUV.WX@` B C "`` D0C hB  s *DԔ"  0 "{4  LUSQdkYkHrh7h_     0ܣ "  8USQdkYkHre,g7h_ ,{N~ ,{ N~ ,{V~ ,{N~    6 #" `` `  X*    6 #" ``   Z*    6( #" `` `  \* H  0޽h ? fffff___PPT10i. +D=' = @B +  Radial   t l `  (   :T H X    "H X "   <lp"X  F 0C    Bl>"H0 F 0C B   C  lBCE6FGIQSTUV.WX@` B C "h  D0C B   s *Dp"p,$ 0  0Xl "py l LUSQdkYkHrh7h_    0xl "x  l NUSQdkYkHroRh7h_   64l #" `` ` l X*   6Hl #" `c  l Z*   6l #" `` ` l \* H  0޽h ? fffff80___PPT10. 0 00(  x  c $'l py l x  c $(l x  l H  0޽h ? 3380___PPT10.8$  $(  r  S fl{4  l r  S  l H  0޽h ? fffff80___PPT10.e>:  p$:(  $r $ S `{l{4  l  $ S 4l  l "p`PpH $ 0޽h ? fffff80___PPT10.\V  (V(  (r ( S l   l  ( 0ӼP0 D Introduction 2 ,H ( 0޽h ? fffff80___PPT10.&$  ,$(  ,r , S `l{4  l r , S  l  l H , 0޽h ? fffff80___PPT10.H$  0$(  0r 0 S l{4   r 0 S l   l H 0 0޽h ? fffff80___PPT10.$  4$(  4r 4 S ,l{4  l r 4 S lP l H 4 0޽h ? fffff80___PPT10.p҉5V  8V(  8 8  <l c"$` P p0  l  8 lhA image002  l 8 0lP FLiquid Filling 2,H 8 0޽h ? fffff80___PPT10.п ~X  <X(  <r < S A  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image004.jpg p  U 0 d B  ` <  D Longer piston stroke  d B` ` 0DG  y Figure 20.7 Volume adjustment $   d <0    R;u 6 U 0H d 0޽h ? fffff80___PPT10.@0/$  h$(  hr h S  {4    r h S  p   H h 0޽h ? fffff80___PPT10. e  ~v l(  lr l S  {4    N l  L5#-A   D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image022.jpg   l BP  \w  C Machined surface  l s ;c5A  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image018.jpg  l Bh  w  5 Rings  l A/A  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image020.jpg@p  l B   w  Cuffs   l <  0P4  ZFigure 20.8 Three methods to keep product from leaking out around piston[[H l 0޽h ? fffff80___PPT10.iO$  p$(  pr p S  {4   r p S      H p 0޽h ? fffff80___PPT10.iE   }u t (  tr t S ! {4    t  vGPSAH 4-51-1f"`@0   v t @{PSAH4-51-1s"`@  v t @{JXAH4-51-1t"`@`  v t @{VSAH4-51-1o"`@p  t BH$  d  u Figure 20.9 Nozzle types $&  t 00 W 0>  dR;u 1 R;u 2 R;u 3 R;u 433!h   7 U 09 U 0: U 0 $; U 0.2H t 0޽h ? fffff80___PPT10.PF$o$  x$(  xr x S , {4   r x S - 0   H x 0޽h ? fffff80___PPT10.S"  |"(  |r | S  ; {4   | |  A  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image008.jpg" P 0 U 0   | BT=  @ * Figure 20.10 Diaphragm volumetric filler $+(* | <TF] @ R;u < U 0H | 0޽h ? fffff80___PPT10.g-$  $(  r  S LD {4   r  S  E P0   H  0޽h ? fffff80___PPT10.K:  :(  r  S S {4     S TY P   "p`PpH  0޽h ? fffff80___PPT10.@U  (  r  S da {4     l07A IMAGE006P `     <le    rBStationary Top Plate Stationary Teflon Plate Rotating Bottom PlateCC  B k  P  8 Filling    Bf @t  Filled  Bo  \ & Figure 20.11 Rotating metering discs $'$&H  0޽h ? fffff80___PPT10.@$   $(  r  S $x {4   r  S x @   H  0޽h ? fffff80___PPT10.0e҄(  @((  r  S h {4   r  S ( `   4  w8A D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image014.jpg p   U 0  Bh l X Figure 20.12 Rotary pump filler !  <] R;u = U 0H  0޽h ? fffff80___PPT10.z>$  0$(  r  S d {4   r  S  p   H  0޽h ? fffff80___PPT10.Ba$  P$(  r  S t {4   r  S 4    H  0޽h ? fffff80___PPT10.A7G  f^`(  r  S  {4   T  # E;NNA  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\403.files\image010.jpgp     B, P D7 v Figure 20.13 Auger filler $H  0޽h ? fffff80___PPT10.,H$  p$(  r  S  {4   r  S x `   H  0޽h ? fffff80___PPT10.xJ$  $(  r  S p̌ {4   r  S D͌    H  0޽h ? fffff80___PPT10.$  $(  r  S ٌ {4   r  S ڌ p   H  0޽h ? fffff80___PPT10.`  h`(  r  S  {4   |   A  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\404.files\image015.jpg"P 0  U 0    B   Z"Figure 20.14 Pure gravity filling #!  <D~] 0 R;u > U 0H  0޽h ? fffff80___PPT10.@db$  $(  r  S  {4   r  S  p   H  0޽h ? fffff80___PPT10.c$  $(  r  S  {4   r  S D @   H  0޽h ? fffff80___PPT10.K e#  #(  r  S " {4     ZA 20"`X     B$  0l Y!Figure 20.15 Pure vacuum filling "   <(] < R;u ? U 0H  0޽h ? fffff80___PPT10.qRf$  $(  r  S h& {4   r  S ,    H  0޽h ? fffff80___PPT10.(g$  $(  r  S 9 {4   r  S `: `p   H  0޽h ? fffff80___PPT10. $ P 7 w Figure 20.30 Vibrating fill $H ` 0޽h ? fffff80___PPT10.$  pd$(  dr d S D {4   r d S E    H d 0޽h ? fffff80___PPT10.@d1  aYh(  hr h S R {4   | h  M-A)  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\407.files\image014.jpg"Pp 0 U 0   h <S ` 0G  OFigure 20.31 Balance beam scale H h 0޽h ? fffff80___PPT10.|r{  l{(  lr l S Z {4   B l !A*  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\407.files\image015.jpgp 4    l B\ p    ]#Figure 20.32 Spring balance scale $" l Bx`  Y !  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What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which the  !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~      !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~      !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~      !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~      !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~      !#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}~     AA * !"#$%&'()+,-./01@BCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{}~Root EntrydO)cPicturesyC Current User",SummaryInformation(XPowerPoint Document("۪DocumentSummaryInformation8.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (dq[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ___PPT9345679:;<=>?@ABI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  um (  r  S \ {4      l'! ! A 20"`p   Z  S $JA20"` 6p   B( ` 0DG  Filling   B    6 Filled   B  g ' Figure 20.19 Pressure gravity filling $(%'  <] vg R;u B U 0H  0޽h ? fffff80___PPT10.`Pr7v2? ^(  > B@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53  !Oh+'0( px    (PowerPoint PresentationoweRadialiTOADli117Microsoft PowerPointon@0h!@@@ԃc,Gg  sN  y-- @ !y--'f--N%%$$%%' ( * , . U W X Z\]^^^^^^]\ZXWU.,*('%%$$$--'-- @ !}--f-- $!!--'ff--,$"%(+.1357788--'--%55--'@Arial-. 2 + Lesson 20 ."System-@Arial-. 2 G-Filling Systems.--.  2 Q..-@Arial-.  2 Q620.--.  2 Q=.--. 2 QF װϵͳ.-D_㷪TOADTOADy find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  um (  r  S \ {4      l'! ! A 20"`p   Z  S $JA20"` 6p   B( ` 0DG  Filling   B    6 Filled   B  @g ' Figure 20.19 Pressure gravity filling $(%'  <] vg R;u B U 0H  0޽h ? fffff80___PPT10.`Pr7wb2? h^<(   C@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p5      !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz{|}3.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (dr[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ___PPT9345679:;<=>?@ABCI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  :20(  r  S l1{4   N   yA R D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\406.files\image011.jpg`    B3 D  Z"Figure 20.20 Cup or Flask Fillers #!  <$] F  R;u C U 0H  0޽h ? fffff80___PPT10. #rh@#;? h'^Ⱥ(   D@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXEdDR;uD../jiaoxueluxiang/flash/20-P66.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (ds[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ >___PPT9 345679:;<=>?@ABCDI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  zp$(  $r $ S {4    $ 3  Q2A   D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\406.files\image002.jpg" 0 U 0  $ Bml <  h0Figure 20.22 Flooding or Constant Stream Filler 1/ $ <] @  R;u D U 0H $ 0޽h ? fffff80___PPT10.KБr(D?? '^Ⱥ(   D@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXEdDR;uD../jiaoxueluxiang/flash/20-P66.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (dt[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ >___PPT9 345679:;<=>?@ABCDI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the produ      !"#$%&'()*+,-./0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ[\]^_`abcdefghijklmnopqrstuvwxyz|}~ct s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4Y  ,Y(  ,r , S ȍ{4   B , A!  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\406.files\image008.jpgP   , Bl M Figure 20.23 Auger filler , <'( V *R;u H , 0޽h ? fffff80___PPT10.0+Wrr8FA? i^X(   E@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXEdDR;uD../jiaoxueluxiang/flash/20-P66.EXEhER;uH../jiaoxueluxiang/flash/20-P67-D.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (dt[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@89ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0>___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ^___PPT9@345679:;<=>?@ABCDEI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  !,(  ,r , S ȍ{4   B , A!  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\406.files\image008.jpgP   , Bl M Figure 20.23 Auger filler , <'( V R;u E U 0H , 0޽h ? fffff80___PPT10.0+WrrFcA? g^X (   F@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXEdDR;uD../jiaoxueluxiang/flash/20-P66.EXEhFR;uH../jiaoxueluxiang/flash/20-P67-D.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (dt[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJK LMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@89ʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0>___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ^___PPT9@345679:;<=>?@ABCDFI Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  +#,(  ,r , S ȍ{4   B , A!  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\406.files\image008.jpgP   , Bl M Figure 20.23 Auger fillerH , 0޽h ? fffff80___PPT10.0+Wr  B:4(  4r 4 S {4    4  n5Y&A" 4-67-2"` x  h 4 c 2mA#4-67-3"` `  4 <$   .Figure 20.24 Auger for nonfree-flowing powder /- 4 B, +  0 Figure 20.25 Auger for free-flowing powder 100 4 < @@ ' R;u F U 0H 4 0޽h ? fffff80___PPT10.mrgFZ#H'C? g,^(   G@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53.exep53.exe8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXEdDR;uD../jiaoxueluxiang/flash/20-P66.EXEhFR;uH../jiaoxueluxiang/flash/20-P67-D.EXEjGR;uJ../jiaoxueluxiang/flash/20-P70-UP.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (du[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJK LMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8Yʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0^___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ~___PPT9`345679:;<=>?@ABCDFG?  %I Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric                           ! " # $ % & ' ( ) * + , - . / 0 1 2 3 4 5 6 7 8 9 : ; < = > ? @ B C D E F G H I J K L M N O P Q R S T U V W X Y Z [ \ ] ^ _ ` a b c d e f g h i j k l m n o p q r s t u v w x y z { | }  Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. The product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4  H(  Hr H S {4    H #  A%  D:\My Documents\FoPT courseware\Sňb/gW@xYZSOSYef[oN\En_text\CH4\407.files\image013.jpg"' 0 U 0  H B4 PT xFigure 20.27 Net weight fille  H <  |  R;u G U 0H H 0޽h ? fffff80___PPT10.^,r;-MAH? -e^(   G@P48-D.EXEP48-D.EXE<p49r.exep49r.exe@p51-d.exep51-d.exe8p53.exep53.exeEXE8 p56.exep56.exe@ p58-d.exep58-d.exe8p66.exep66.exeDP70-UP.EXEP70-UP.EXE@p72-d.exep72-d.exe8P73.AVIP73.AVI`3R;u@../jiaoxueluxiang/flash/20-1.EXE`4R;u@../jiaoxueluxiang/flash/20-2.EXE`5R;u@../jiaoxueluxiang/flash/20-3.EXE`6R;u@../jiaoxueluxiang/flash/20-4.EXE7R;u 1 H../jiaoxueluxiang/flash/20-P51-1.EXEl9R;u 2H../jiaoxueluxiang/flash/20-P51-2.EXEl:R;u 3H../jiaoxueluxiang/flash/20-P51-3.EXEl;R;u 4H../jiaoxueluxiang/flash/20-P51-4.EXEh<R;uH../jiaoxueluxiang/flash/20-P51-D.EXEd=R;uD../jiaoxueluxiang/flash/20-P53.EXEd>R;uD../jiaoxueluxiang/flash/20-P56.EXEd?R;uD../jiaoxueluxiang/flash/20-P57.EXEh@R;uH../jiaoxueluxiang/flash/20-P58-D.EXEdAR;uD../jiaoxueluxiang/flash/20-P60.EXEdBR;uD../jiaoxueluxiang/flash/20-P61.EXEdCR;uD../jiaoxueluxiang/flash/20-P64.EXEdDR;uD../jiaoxueluxiang/flash/20-P66.EXEhFR;uH../jiaoxueluxiang/flash/20-P67-D.EXEjGR;uJ../jiaoxueluxiang/flash/20-P70-UP.EXE/ 0DArialBlact+8 08z[ 00"D[SOalBlact+8 08z[ 00 DTimes New Roman8 08z[ 000DWingdingsRoman8 08z[ 00@DArial Blackman8 08z[ 00"PDўSOal Blackman8 08z[ 00@ .  @n?" dd@  @@``   (du[             ! "#$%&'()*+,-./02346789: ;<=>?@ABCDEFGHIJK LMNOPQRSTUVWXY Z[\]^_`aR$NLD?'GvlAb$V9A$gq6 Ab$޷|ta):e-KR$N`JHG.Œs9NR$5/j946&'ab$\!0ZU',R psR$f FYlg, “R$ShUa/d| R$mwn^; R$J^n@h R$fOVo遪!@4D oR$Ln.fR' tR$H倬hߕ0/Đ R$ijFKu5*2WR$6Z ޸9M +_6R$UMRMMк-UR$[pTmPX 0͈X0R$E&H7t\tA8CR$pyW_.R$cf"練k9R$[L,?8U;5 NR$P0:tFv?a[R$ ;K(܊^*LccR$Q $A7#.n;2 R$=dԯiCh/=R$Yx CyAfe1R$1M{'J"Ri[oR$_"’C I)p2R$rc.-fR$f<˦D - R$f\j^du:(R$y|O j> 0AA@8Yʚ;ʚ;g4NdNdPz[ 0ppp@  <4dddd|< 0^___PPT10D[SOes New Ԥ0Ԥz[ 0̤DTimes New RomanԤ0Ԥz[ 0̤ ~___PPT9`345679:;<=>?@ABCDFG?  %I Lesson 20  b Filling Systems ,{20 EQkXLpň|~(2, 4 ^Y content Introduction Liquid Filling Liquid Volumetric Filling Liquid Constant Level Filling Dry Product Filling Dry Volumetric Filling Dry Filling By Weight Filling By CountDZ Introduction , 1. What a filler can be asked to do? Fillers, filling machines, are used to transfer many types of products from bulk storage bins and vats into the containers in which they find their way to the market. The great variety of products that are packaged and the containers that they fill has caused the development of a large number of processes, techniques, and machines that are used for product filling. B 2. Considerations in selecting a filler Types of products: from very thin liquids to semi-liquid products, pastes, and solids; stable, volatile, explosive, hot, frozen products. Size, shape, and construction of the containers: glass bottles and jars, plastic bottles and cartons, paperboard boxes, metal cans, and plastic or paper bags. Way the product is measured: by volume, weight, or count. )c'w1n Introduction Desired speed of the operation: a relatively slow manual operation, semi-automatic, fully automatic ( high speed lines) Special handling requirements of the product Cost of installation Operation ^ XL Liquid Filling,1. Introduction Liquid products: alcohol and soda water Semi-liquid products: toothpaste, peanut butter, and caulking compound \o2 Liquid Filling,2. Types of Filling Machines The containers may be made of plastic, metal, glass, treated paperboard, or a number of other materials. The shapes of the containers include those of bottles, jars, vials, tubes, cans, pouches, cartons, and drums (Figure 20.1). < (Figure 20.1 The shapes of the containers))   Most liquid and semi-liquid products are filled by one of two major methods: volumetric, or constant level filling. In volumetric filling the amount of product is premeasured so that each container has the same volume of product. Constant level filling techniques fill each container to the same level, so it is frequently called the  fill-to-a-level method.FjL&  Liquid Filling3. Use of Filling Machines Volumetric filling is particularly appropriate for applications in the pharmaceutical industry where it is important that each container is accurately filled with a specific volume of product. Constant level filling is used with see-through bottles in which it is important that all of the bottles in a display appear to be filled to the same level, although the bottles may not be exactly the same size and the volumes may be slightly different., Liquid Filling*4. Rotary and Straight-line Fillers The rotary filler removes the containers from the conveyor onto a rotating plate which carries them in a circle through the filling machines. The filling heads rotate with the containers as they are filled, so that there is a continuous motion (Figure 20.2). 8$$ Liquid FillingThe straight-line fillers fill each container as it moves along the conveyor in a straight line. a) This may be an intermittent motion operation in which the conveyor is stopped until the container is filled, then it is moved just far enough to place the next container in position under the filling nozzle. b) It may fill only one or a number of containers in each operation depending upon the number of filler heads that are used.  Liquid Fillingc) Some multiple head machines have the capability of following the containers along the line and filling them in a continuous motion without stopping the filling line (Figure 20.3).   Liquid Volumetric FillingsIntroduction Definition: Volumetric fillers deliver a premeasured volume of product to each container, and the volume of product in each container is held constant. Advantages: accuracy, flexibility, and reliability in addition to being relatively easy to clean. Three popular types of volumetric filling methods: piston operation, diaphragm action, and timed flow. d   U277 2 Liquid Volumetric Filling1. Piston Volumetric Filling A piston filler (Figure 20.4) measures and delivers the product to the container by the action of a single piston for each filler head. :"Liquid Volumetric Filling Liquid Volumetric FillingL Types of valves: a reciprocating valve and a rotating valve (Figure 20.6). @L;KLiquid Volumetric FillingThe volume of product delivered into the container is determined by the volume of the filling chamber in which the piston is operating. This volume can be changed by adjusting the length of the piston s stroke. As the stroke is lengthened, the volume of the chamber is increased, and as the stroke is shortened, the volume of the chamber is decreased (Figure 20.7).nZnLiquid Volumetric Filling Liquid Volumetric FillingFigure 20.8 shows three methods that are used to keep the product from leaking out around the piston as it moves back and forth: fine tolerance, rings placed in grooves around their circumference and cuffs applied to the ends of the pistons to create a seal. $Liquid Volumetric Filling Liquid Volumetric FillingDifferent types of products require different nozzle designs and sizes (Figure 20.9). Filler nozzles are designed in different sizes and shapes to prevent splashing, foaming, or excessive aeration of the products during filling. $Liquid Volumetric Filling Liquid Volumetric Filling2. Diaphragm Volumetric Filling The diaphragm type volumetric filler uses a flexible diaphragm and pneumatic pressure to move premeasured amounts of product from the supply tank into a controlled volume chamber and into the container. The diaphragm volumetric filling systems are generally used to fill small-necked bottles with relatively expensive products because of their high level of accuracy and the small loss of product in filling. B! 1Liquid Volumetric Filling Liquid Volumetric FillingF3. Timed Flow Volumetric Filling The volume of product in each fill can also be regulated by controlling the amount of time the product flows at a constant rate through a standard sized tube into the container. Three popular ways of measuring and regulating the flow time are rotating metering discs, rotary pumps, and augers.@!&&Liquid Volumetric Filling11) Rotating Metering Discs The filling head consists of two stationary plates and a bottom rotating plate (Figure 20.11). When the openings in the three plates are in alignment, the product is free to pass through into the container. The flow ceases when the rotating bottom plate moves out of position..Liquid Volumetric Filling  Liquid Volumetric FillingThe volume of the fill can be regulated by changing the size of the opening, or slot, in the center plate or by changing the speed of the rotating plate. This filler can double fill a container by passing it under two stations, or two or more different materials can be filled into the container by supplying different products at the different filling stations. The volumetric filler using metering discs can handle a wide range of liquid products and some semi-liquid products that may be as thick as peanut butter.  Z "Liquid Volumetric Filling2) Rotary Pumps Rotary pumps (Figure 20.12) are used for volumetric filling by regulating the operating interval of the pump to control the amount of product that is delivered. @!Liquid Volumetric FillingYThe product flow is controlled by electric or air operated clutch and brake mechanisms that can start and stop at very precise intervals. Some fillers measure the product flow with a revolution counter attached to the drive shaft of the pump, and the flow is regulated by adjusting the number of turns that the pump impellers make on each fill. ZZ#Liquid Volumetric Filling3) Augers Semi-liquid products that are too thick to be moved by a rotary pump may be filled by a similar filler that uses an auger in place of the pump to move the product. The volume of product delivered by an auger filler (Figure 20.13) is controlled by the amount of time the auger turns or the number of turns it makes on each fill, in much the same manner that is used for rotary pumps. Some auger fillers use an agitator rotating in the product hopper to keep the product moving smoothly and maintain an even consistency.2 PP $$Liquid Volumetric Filling % Liquid Constant Level FillingIntroduction It is frequently desirable to have the fill line at the same height on each container so that all of them appear to be filled exactly the same when they are on the display shelf. Some manufacturers deliberately add extra product and overfill some of their  see through containers in order to improve their appearance and to guarantee that all of them contain at least the minimum desired amount of product. Constant level filling techniques compensate for the minor changes and variations in the containers and produce the uniform appearance that is important in the sale of many products in  see through containers.. PlP l&!Liquid Constant Level FillingOFive basic methods used for constant level filling of still liquids and semi-liquids: Pure gravity filling Pure vacuum filing Gravity vacuum filing Pure pressure filling Level sensing filling One method used for filling carbonated products: Pressure gravity filling V1(V 1'"Liquid Constant Level Filling1. Pure Gravity Filling Being not only one of the oldest and simplest constant level filling methods, but it is also one of the most accurate ones for filling free-flowing products(Figure 20.14). Used for most still liquids and some semi-solids. The product flow is produced by locating the product supply tank high enough so that forces of gravity can be used to move the product through the feed mechanisms into the containers.BZZ(#Liquid Constant Level Filling )$Liquid Constant Level FillingThe maintenance requirements are relatively simple. The consistency of the product and the free movement of all moving parts are critical for smooth operation. *%Liquid Constant Level Filling2. Pure Vacuum Filling Used primarily for filling narrow necked glass bottles with still liquids (Figure 20.15). Not normally used with plastic or other non-rigid containers. Generally faster than a pure gravity system, but has some overflow and recirculation of product. The vacuum filler works only when there is a seal between the bottle and filler valve, so chipped or cracked bottles can not be filled.V+&Liquid Constant Level Filling ,'Liquid Constant Level FillingA vacuum level of between 25 and 28 inches of mercury is normally maintained to provide smooth and efficient operation. Somewhat more difficult to clean than a simple gravity system because of its complexity and small vacuum tubes that can become plugged. The proper type of filling nozzle is always used for the product being filled, because foaming, aeration, and splashing can be increased by rapid movement of the product.Z-(Liquid Constant Level Filling3.Gravity Vacuum Filling Combining the features of both the gravity and the vacuum systems(Figure 20.16). A light vacuum of from 3 to 5 inches of mercury is maintained in the system to assist in drawing the air out of the containers and to stabilize the flow of the liquid. Having not the overflow or recirculation of product that is inherent in the pure vacuum system, and it produces minimum amounts of turbulence and aeration of the product. >S^.)Liquid Constant Level FillingParticularly well suited to filling distilled spirits and wine because there is virtually no loss of proof. A chipped or cracked bottle on which a seal is not formed will not be filled./*Liquid Constant Level Filling 0+Liquid Constant Level Filling4. Pure Pressure Filling The product is pumped from a storage tank through a filling valve and into the container(Figure 20.17). Hiih 1,Liquid Constant Level Filling`When the product reaches the overflow port, the fill is completed, but the flow continues through the overflow tube until the seal on the container is broken and the valve sleeve covers the ports in the filling nozzle and stops the flow. Normally used for still liquids, but it can be applied to a wide variety of products with different consistencies.aa3.Liquid Constant Level FillingApplying pressure to the product may tend to increase splashing or foaming. Regular cleaning and lubrication of all moving parts.  4/Liquid Constant Level Filling5. Level Sensing Filling Making it possible to fill containers to a level without establishing an airtight seal between the tops of the containers and the filler valves (Figure 20.18).<50Liquid Constant Level FillingKUsed primarily for high speed filling of small necked plastic and glass bottles. The fill level is very accurate, and there is no need for product recirculation. The sensing device operates by directing a stream of low pressure air at the filling station and detecting changes in the resistance to the air flow. The positioning of the filler and the start of the flow can be initiated when the sensing device detects the presence of the empty bottle in the filling station. When the product has filled to the desired level, the sensing unit signals the interface valve to stop the flow.LZL61Liquid Constant Level Filling6. Pressure Gravity Filling Pressure gravity filling (Figure 20.19) is a process that was developed specifically to help hold the CO2 in the carbonated beverages during the filling operation. This method is used almost exclusively for filling beverages such as sodas, beer, sparkling wines, and champagnes into bottles or cans. A pressure of between 15 and 125 psig is maintained in the headspace of the product supply tank to help hold the CO2 in solution. tZZh 7 72Liquid Constant Level Filling 83Liquid Constant Level FillingWhen the container is sealed to the filling valve a mechanical latch opens a charging valve at the top of the valve vent tube. This establishes in the container the same pressure level that is being applied to the surface of the product in the supply tank. T he product is in a totally pressurized environment. This pressure does not interfere with the filling process, but it does prevent the loss of carbonation.P94Liquid Constant Level Filling%After the pressure in the container is equalized with that in the supply tank, the spring loaded filler valve opens and the product flows into the container by gravity until the vent port is covered and the flow is stopped as in a normal gravity filling process. The filling valve also contains a mechanical snift port which opens the headspace of each filled container to the atmosphere in order to gently release the pressure from the filled container and prevent gushing when the seal is broken and the filler head is removed from the container. &%PP&4:5Dry Product FillingR1. Introduction Dry products: light, heavy, sticky, very dry, flowing freely, some moved by force. The containers: as small as a capsule or as large as a one hundred pound bag or a 55 gallon drum. They can be boxes, cans, bottles, pouches, bags, drums, or other forms, and they may be made of a variety of rigid and flexible materials. C D;6Dry Product Filling2. Types of Dry Products Rice and beans, are free flowing and easy to move. Fine powders (confectioners sugar), may be hard to contain in the bins or containers and can cause a dusty or explosive atmosphere. Nails, bolts, and other hardware items may require special handling because of their weight, bulk, or shape. Cornflakes and light bulbs must be protected from breakage during packaging. Ice cream bars must not be allowed to melt. Special care is needed to keep food packaging sanitary and drugs sterile.8PP<7Dry Product Filling3. Types of Dry Filling Operations There are four basic types of dry filling machines based upon the way the amount of product being delivered is measured: By volume: the volumetric fillers deliver a constant volume of product to each container. By net weight: the net weight filler weighs the product before it is delivered into the package. By gross weight: the gross weight filler weighs the product in the container By count: the counter places the same number of items into each container.:#PyPtP"$$y M R< A=8Dry Product Filling4. Product Delivery Free flowing dry products are frequently delivered to the filling machine through gravity feed system. Other products are delivered by vibrator systems in which vibrating pans cause the product to  walk into the filler. Augers are used to move the nonfree-flowing products that are sticky or have other characteristics that make them difficult to handle.4eed>9Dry Volumetric Filling "Introduction Loading an exact volume of product into each container without consideration of the product s density or weight. Delivering a constant volume does not always produce a constant weight. Four popular types of volumetric fillers used with dry products are : Cup or flask fillers Flooding or constant stream fillers Auger fillers Vacuum fillers.d PPP  |?:Dry Volumetric Filling 1) Cup or Flask Fillers Getting its name from the cup or flask that is used to measure the amount of product that is delivered (Figure 20.20). The sides of the cups telescope so that the cup size can be adjusted to the exact volume that is needed.F@;Dry Volumetric Filling  A<Dry Volumetric Filling vWorking particularly well with free-flowing granular products. Normally used for products in which the density or unit weight is relatively constant or when the volume of the product that is delivered is more important than the weight. Usually used when the size variations are relatively small or the gained speed and economy more than offset the cost of the extra product that is being used. Figure 20.21 shows a top view of a twelve head rotary filler with a scale on one cup. Machine adjustments may occasionally be needed to correct conditions of underfill, overfill, excessive recirculation, or spillage at the container. wPw* DB=Dry Volumetric Filling  C>Dry Volumetric Filling 2. Flooding or Constant Stream Fillers The fillers work on the principle that containers passing under a constant stream of product in the same amount of time will all receive the same amount of product (Figure 20.22). Any variations in the speed of the container as it travels under the filler affects the volume of the fill. Changes in the rate of product flow from the hopper can also affect the volume of the fill. P(~#|D?Dry Volumetric Filling  E@Dry Volumetric Filling 3. Auger Fillers Use a rotating auger in a funnel shaped hopper to deliver a specific amount of product at a constant rate(Figure 20.23). The volume of the fill is determined by the extent of the rotation made by the auger. Some auger fillers have timing mechanisms that allow the auger to turn for a preset time on each fill, and other designs count the number of rotations that the auger makes on each fill. J w FADry Volumetric Filling GBDry Volumetric FillingUsed for a wide variety of products, but they are particularly appropriate for products that tend to bridge over the openings, such as finely ground coffee, cake mixes, and flour. The auger shown in Figure 20.24 is used to move nonfree-flowing powders, and the auger shown in Figure 20.25 is designed to provide an even flow of free-flowing powders while preventing the natural flow when the auger is not turning. $ZZHCDry Volumetric Filling IDDry Volumetric Filling#4. Vacuum Fillers Similar to the fill-to-a-level operations used with liquid products (Figure 20.26). They use the container as a measure of the fill. A vacuum is used to draw off excess product and to tamp the product for a tight fill or preventing product dust from escaping into the air.,JEDry Volumetric Filling KF Dry Filling By Weight $}Introduction For some products the weight of the product in each package is more important to the user than the volume, and the cost of the product may make it uneconomical to deliberately overfill some of the containers in order to guarantee that they all contain a minimum weight. There are two basic techniques for filling by weight: net weight and gross weight filling systems.p q D  LG Dry Filling By Weight $-1. Net Weight Filling Being the most accurate of the filling techniques. Each product load is weighed separately in the filling machine before it is loaded into the container (Fig.20.27). Easily used for filing bags and other flexible containers that must be supported during the filling operation.4MH Dry Filling By Weight $ NI Dry Filling By Weight $aThe accuracy of the net weight fill can be affected by the amount of product in the stream when the shutter closes to stop the fill. A two-stage net weight fillers (Figure 20.28) are used to increase their accuracy and speed. In the first stage the bulk of the fill is dropped rapidly into the chamber by a large filling spout, then the chamber is moved under a smaller spout that dribbles in amount of product that is needed to complete the fill. This type of system allows the container to be filled more rapidly while keeping the amount of product in the stream at a minimum when the shutter is closing. (aZZbOJDry Filling By Weight PK Dry Filling By Weight $2. Gross Weight Filling In gross weight filling (Figure 20.29), the product is weighed inside the container as it is filled, and the scale operates a signaling device that operates the filler. Filling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another.4QL Dry Filling By Weight $ RMDry Filling By WeightFilling by gross weight is faster than by net weight, because it requires one less step. It is also preferred for handling more fragile products such as cornflakes and potato chips that can be broken or crushed by handling, since they can be moved gently into the package without dropping them from one container to another. Some products, such as brown sugar, may need to be settled into the package during the filling process in order to obtain a tight pack. (ZZSNDry Filling By Weight TODry Filling By WeightTypes of Scales The four types of scales commonly found on filling machines are: Balance beam scale (Figure 20.31) Spring balance scale(Figure 20.32) Air balance scale (Figure 20.33) Liquid displacement scale (Figure 20.34) bAA hUPDry Filling By Weight VQDry Filling By Weight WRFilling By CountMIntroduction Nuts, bolts, capsules, cookies, and a wide variety of other products are marketed by number rather than volume or weight. Four popular techniques are frequently used for filling products by count: Board or disc counters Slat counters Column counters Electronic counters.\ z zXSFilling By Count1. Board or Disc Counters The product is dropped or brushed into a group of holes in a disc or board and moved to a position from which it is dropped into the container, the number of items in each fill is determined by the number of holes in the area of the board or disc that is used. This technique is widely used in the pharmaceutical industry for filling containers with tablets.@h$hYTFilling By Count ZUFilling By Count2. Slat Counters. The slat counter is a chain driven conveyor made up of slats which have pockets or cavities to hold product items(Figure 20.36). X$  [VFilling By Count \WFilling By Count23. Column Counters Products that have a constant thickness and flat surfaces, such as cookies, tablets, or washers, can be mounted by measuring the height of stacks of the product. Single track machines with only one column may be used, or machines with two or more tracks may be used to gain extra speed.@ ]XFilling By Count4. Electronic Counters Use electric-eyes or other sensing devices to detect the product item passing a given point. Can count objects of a wide variety of sizes and shapes with only minor change-over procedures. 4rQ? }^